System to determine in near real-time product density in a continuous dispensing product flow

ABSTRACT

A system for determining in near real-time the product density value of a zone of preferable small fungible products within an acceptable size range in a flow of products includes a sample input piping from a bin or piping of products, a sampling volume for fixing the size of a sample, a scale, a processor, an imaging table and an associated camera. The system may include a sample output pipe, and may include or be associated with a bagger/scale. Operation of these components provides for successively sampling of each zone in the bin to determine the quantity of acceptable product per unit weight and to control the flow of those products. The system therefore can compensate for variations among supplying entities where product supplies are subsequently piled atop one another. The system makes the density calculation available to the plant information system and an automated packaging system, which may be via a 16 bit scaled analoge or a serial interface, among other systems. In addition the image information is stored for future analysis, audit support, and process improvement activities.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 61/152,930 entitled “Seed count estimator” filed on Feb.16, 2009 in the United States Patent and Trademark Office and which isincorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention pertains to systems for providing an approximatecount of small fungible products, such as seeds and plastic pellets.More particularly the present invention relates to determining thedensity of the fungible products in a unit volume in an associated orparallel product flow so the system or a separate connected system candispense a close approximation of a specific quantity based on thevolume calculation derived from product density rather than dispensingby estimated weight only. The user now has the ability to vary theweight in order to achieve a very accurate piece count.

2. Description of the Related Art

Processing operations for seeds provide a clear background for thepresent type of system. In traditional seed processing operations, theoperator receives bulk deliveries of the desired seed, which includeundesirable elements in each delivery; which may also include hulls,rocks, insects, plant matter, weed seeds, and pieces of desirable seeds.The operator utilizes various equipment to remove these undesirableconstituents, leaving only whole desired seeds. This may includereceiving, cleaning, treating, potentially storing, and packing seed forpurchase, typically by weight. While purchase by actual number of seedsis desirable, due to variations in source and timing, in processing toremove undesirable constituents, the number of seeds per unit weight,the seed density, varies. Additionally, when seeds of differingsuppliers are combined, the seeds received may vary in size and moisturecontent yielding much different densities from supplier to supplier. Dueto these variations, operators have historically been unable toaccurately deliver a specific number of seeds per package, where thepackage in question may range from fifty (50) pounds to ten thousand(10,000) pounds. This creates issues for purchasers, among others, whodesire to purchase a certain quantity of seeds, typically enough forseeding of a particular area but not so much as to have leftover, andoften thereafter unusable, seed. Leftover seed may be unusable becauseof storage issues, germination period, and, particularly with the riseof genetically-modified and patented seeds, most importantly legalpermissions. Thus, inconsistent seed counts can create substantialissues, sometimes providing an insufficient or wasteful quantity ofseeds when computed on the anticipated planting rate. When attempting toprovide seeds based on quantity, operators have intentionallyunderestimated the number of seeds likely to be a particular weight bagso as to guarantee purchasers receive enough seed. This, however,results in waste as unnecessary, and therefore unusable, seed isprovided to purchasers. Moreover, operators lose potential revenues oneach sale solely to ensure sufficient seeds per sale. Regulatoryauthorities are requiring the industry begin labeling the seed packagingwith the “count” or number of seeds per container. In addition theprocessor may desire to purchase seeds by the count rather than weight.While not tested for this application the invention could provideutility in this and many other bulk product handling facilities.

Attempts to provide accurate seed counts have focused on providing atrue count of seeds by processing each seed through a counter. Oneattempt at resolving this situation has provided for each single seed tobe drawn past a photoelectric sensor and individually counted. Inanother attempt, a sampling of seeds is vibrated past a series ofphotodetector cells or seed counters and individually counted, and thenweighed, to determine a theoretical mass for the desired seed count.Problematically, these systems require that each seed be actuallycounted, which results in substantial reduction in speed of processingand which does not adequately address the issue of broken seeds, and ofdistinguishing individual seeds which are larger than the standard sizefrom clusters of seeds. In another attempt in the prior art, an image ofuniformly-sized, and ideally uniformly-distributed, seeds on ahorizontal surface is processed to determine average object size andextrapolated to determine an estimated total object count for the imagedseeds. Problematically, this system provides only a estimated countbased on computer average size based on a single review and provides nomeans to limit the count being directed to a bag or other output.Moreover, the requirement of a uniform size of seeds can create issuesas seed size may vary significantly. Unequal distribution, particularlydue to clusters of seeds, skews the results.

Additionally, attempts to modify existing systems to include equipmentto provide accurate seed counts have been economically unfeasible,requiring line retooling and capital investment and utilizing systemsgenerating stale data. The current systems require, in some cases, asmuch as 30 minutes to determine the applicable density data. In suchcases, by the time the density date is available, the density of thepassing product may have substantially deviated from the determination,providing data of little utility.

Thus, there is a need in the art for a system for use in productprocessing operations that rapidly determines the density of products,which may be used to obtain a desired product count per bag with littlewaste and which can do so by eliminating broken products from the count,counting the products within clusters, and counting products of varyingsizes. Moreover, there is a need for a system which integrates easilyinto existing operations and the current product handling systemswithout excessive line retooling and without substantial capitalinvestment. There is also a need for a system which integrates with thecurrent plant information and control systems along with theweigh-bagger to provide an accurate method for dispensing a weight thatcontains a very accurate number of objects (seeds), particularly onedesigned to work in-line and support high volume operations.

SUMMARY OF THE INVENTION

The present invention therefore meets the above needs and overcomes oneor more deficiencies in the prior art by a system for use in productprocessing operations that rapidly determines the density of products,which may be used to obtain a desired product count per bag with littlewaste and which can do so by eliminating broken products from the count,counting the products within clusters, and counting products of varyingsizes. Moreover, the present invention provides a system whichintegrates easily into existing operations and the current producthandling systems, thus reducing line retooling and reducing the totalcapital investment. The system integrates with the current plantinformation and control systems along with the weigh-bagger to providean accurate method for dispensing a weight that contains a very accuratenumber of objects (seeds). The system is designed to work in-line andsupport high volume operations.

In one embodiment, the present invention includes a container whichdefines a sample of products, a framework, a scale, a processor, animaging table, and an associated camera. The system may be connected toan automated bagger/scale, a display for a manually-operatedbagger/scale, or to a plant computer system for bagging, qualitycontrol, or record keeping. The invention accurately weighs a sample ofproduct with a high degree of precision, accurately counts the quantityof product in the sample, and determines the value of the productdensity of the associated and larger zone of the product flow.Determination of the value of the product density provides severalbenefits.

Where a desired quantity is to be dispensed, once the product densityvalue is known for a particular zone of product flow, the desiredminimum weight necessary to obtain the desired product count from thatzone may be determined and a bagger/scale controlled to obtain thatminimum weight.

Unlike prior inventions, the invention images or takes a picture of thesample in a two tone, black-and-white, or dichromatic image, countsproducts within a size range, and then uses a morphological process toidentify and count products in clusters or products larger than theproduct range. The system allows the images to be saved in digitalformat to permit future retrieval for use in plant audits and historicalvalidation of the material processes at any given time.

Additional aspects, advantages, and embodiments of the invention willbecome apparent to those skilled in the art from the followingdescription of the various embodiments and related drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the described features, advantages, andobjects of the invention, as well as others which will become apparentare attained and can be understood in detail; more particulardescription of the invention briefly summarized above may be had byreferring to the embodiments thereof that are illustrated in thedrawings, which drawings form a part of this specification. It is to benoted, however, that the appended drawings illustrate only typicalpreferred embodiments of the invention and are therefore not to beconsidered limiting of its scope as the invention may admit to otherequally effective embodiments.

In the drawings:

FIG. 1 is an illustration of one embodiment of the present invention inconnection with an existing product bin, bagger/scale, and bag.

FIG. 2 is a flowchart of steps of the present invention.

FIG. 3 is an illustration of another embodiment of the present inventionin connection with an existing product bin, bagger/scale, and bag.

FIG. 4 is an illustration of a scale used in the present invention.

FIG. 5 is an illustration of the imaging table used in the present.

FIG. 6 is a flowchart of the steps used associated with the processingof an image from the imaging table.

FIG. 7 is a graphical depiction of an image from the imaging table aspart of morphological processing.

FIG. 8 is a graphical depiction of an image from the imaging table aftermorphological processing.

FIG. 9 is an illustration of a damping device which may be placedintermediate the scale and the imaging table.

FIG. 10 is an illustration of a parallel flow system with the presentinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, the invention provides a system which includes asample input piping 102 from a bin or piping 104 of products 106, suchas selected preferable small fungible products and which may be a mixedflow further including undesirable contaminants, through which products106 flow, a sampling volume 108, for defining a sample 140, a weightscale 110, a processor 112, an imaging table 114 and an associatedcamera 116. The invention may include a sample output pipe 118, and mayinclude or be associated with a bagger/scale 120. Operation of thesecomponents provides for successively sampling of each zone 122 in thebin 104 to determine the quantity of acceptable product per unit weight.While this data may be used for later historical review, it may be alsobe utilized with a bagger/scale 120 particularly to determine a desiredweight of product for that zone equivalent to the desired productquantity, and to terminate operation of a bagger/scale 120 when thedesired weight of the product 106 at the bagger/scale 120 is reached,thus adjusting the weight of the products 106 dispensed into each bag124 containing the products 106 based on the associated zone 122. Suchuse may require a dedicated processor or a site-based computer network.If so used, the weight of the bags 124 of the products 106 dispensed bya bagger/scale 120 will vary over time and, dependent on source of theproducts 106 in that zone while the product count for each bag 124 willbe roughly equivalent. This system therefore can compensate forvariations among supplying entities where product supplies aresubsequently piled atop one another.

Still referring to FIG. 1, the sample input piping 102, which may be apipe, or a channel or other structure to communicate seeds, is incommunication with the bin or piping 104. In one embodiment the sampleinput piping 102 penetrates through the side wall of the bin or piping104 to the center of the sample input piping 102, where the sample inputpiping 102 terminates in an upward opening 126. Thus, as each zone 122of the products 106 moves downward a representative sampling of the zonepasses into the sample input piping 102, a flow diversion step 202identified in FIG. 2. The sample input piping 102 has a first end and asecond end, with the sample input piping 102 adapted for communicationwith the sample volume 108 at at the second end of the sample inputpiping 102. The sample input piping 102 is also adapted forcommunication with the bin 104 of products 106, particularly where theproducts 106 are in one or more of said zones 122 in the bin 104. Insuch situations, the products 106 in each of the one or more of saidzones 122 generally have nearly equivalent characteristics of size,weight and percentage of desired products. A gate 128 may be located atthe upward opening 126 to further control the flow into the sample inputpiping 102 but may also be omitted. The sample input piping 102 is alsoin communication with a sampling volume 108 which may include a top gate134 at its top side 130 and a bottom gate 136 at its bottom side 132,defining a sampling container. The sample input piping 102 musttherefore have a sufficient sized opening to draw from a zone 122 of thebin or piping 104. The sample input piping 102 ideally operates on agravity feed, downwardly descending as it passes out of the bin orpiping 104. The sample input piping 102 may be in contact with orconnected to an eccentric or vibratory motor or other vibration-inducingdevice, such as a vibratory feeder 150, to ensure the products 106 donot bridge, or stack atop of or in the sample input piping 102.

In operation, closing the bottom gate 136, step 204 of FIG. 2, definesthe bottom of the sampling volume 108 and closing the top gate 134prevents the addition of further products 106 into the sampling volume108, and therefore defines the sample 140 when filled with products 106,particularly the volume of the sample 140. As can be appreciated, it isessential that the flow of the products 106 be metered to control thevolume of the products 106 introduced to the present invention as asample 140. The top gate 134 may be closed, step 206 of FIG. 2, based ona pre-determined point in operation, which may by time, or a switchlocated in the sampling volume 108. The volume of the sample 140 may bedefined by lengthening the sampling volume 108 or by increasing ordecreasing the usable interior volume of the sampling volume 108, suchas by inserts or interchangeable sampling volumes 108. The sample 140may be collected at the time determined by a processor 112.

Referring to FIG. 3, a return pipe 302 may be in communication with thesample input piping 102 above the top gate 134 to provide a return tothe bin or piping 104 for any products 106 prevented from entering thesampling volume 108, step 208 of FIG. 2. The product 106 contained inreturn piping 302 may be directed to another part of the bin 104 viaconnection of return piping 302 to sample output piping 118 or processedotherwise. Alternatively, the return piping 302 may terminate in anopening 304 in the bin 104 which may be positioned to ensure return ofthe products 106 to the same zone 122 from which it was sampled at thetime the zone 122 reaches the opening 204.

Returning to FIG. 1, in the first embodiment, the sampling volume 108 isalso in communication with a scale 110, such that when the bottom gate136 of the sampling volume 108 is opened, after the sampling volume 108has filled with the products 106 and fixed a sample 140, the products106 of sample 140 contained therein falls onto the scale 110, step 210,which weighs the sample 140 and provides an output to a processor 112,step 212 of FIG. 2, consistent with, and indicative of, the weight ofthe sample 140. Scale 110 is therefore adapted to transmit a sampleweight value to a processor 112, which may function as a weightprocessor. The scale 110 may therefore be positioned below the samplingvolume 108 and receive the sample 140 from the sampling volume 108.

Referring to FIG. 4, the scale 110 is preferably rotatably mounted topermit the sample 140 contained in the scale 110 to be dispensed onto animaging table 114 after the processor 112 records the weight associatedwith sample 140, step 212 of FIG. 2. Scale 110 may therefore be a dumpscale. The scale 110 may be hingely mounted by pins 402 connected to asupport frame 408 and maintained in position by a rotatable orreleasable arm 404 connected to a motor or by piston 406 or may berotatably mounted and rotated about an axis. Alternatively, the scale110 may be fixed in position and associated with a closable dispenser,thereby opening and closing the orifice to permit the products 106associated with the sampling volume 108 in the scale 110 to be dispensedonto an imaging table 114. In a further alternative (not shown), a brushor plow may be associated with scale 110 to push the products off thescale 110 for delivery to the imaging table 114. The imaging table 114may be positioned below the scale 110 and positioned to receive thesample 140 from the scale 110. In each instance, the scale 110 ispreferably emptied in response to a signal from the processor 112, butmay be constructed to empty after a uniform time period. For accuracy,the scale 110 preferably is accurate to at least one hundredth of agram.

Due to the position of the products 106 in the sample 140 in the scale110, products 106 may have increasing potential energy which may betranslated to kinetic energy during the dispensing from the scale 110 tothe imaging table 114. Thus it may be helpful to include a dampingdevice between the scale 110 and the imaging table 114, such as thedamping device 902 depicted in FIG. 9, which dissipates the kineticenergy of the products 106 prior to reaching the imaging table 114. Thismay be accomplished by, among other options, a damping device 902 whichincludes a number of protrusions, such as spaced apart bars or pegs 904,as illustrated in FIG. 9. Such protrusions absorb some of the energy ofthe moving products 106 while only slightly slowing the flow of theproducts 106 in the sample 140 to the imaging table 114. Alternatively,the damping device 802 may include other materials intended to contactproduct 106 during its downward descent and thereby slow the product106, such as rotating paddles or ribbons of material. Alternatively, thedamping device may include a textural profile using long screws withplastic heads to retard the velocity of the falling products 106.

Referring again to FIG. 1, once the products 106 of the sample 140 aredeposited on the imaging table 114, step 214 of FIG. 2, the sample 140,namely the products 106, are imaged by the camera 116, preferably amonochromatic camera of sufficient resolution to identify the edges ofindividual products 106, step 216 of FIG. 2. Camera 116 may bedichromatic, black-and-white, or color. Preferably, the imaging table114 is illuminated from below, thus providing high contrast between thesurface 138 of the imaging table 114 and the products 106 of samplingvolume 108. The processor 112 receives one or more images of the imagingtable 114 via the camera 116 from which a count of acceptably-sizedproducts 106 contained in sample 140 is determined, step 218 of FIG. 2.Camera 116 must therefore be adapted to transmit at leas one image ofthe content of the image table 114 to a processor 112, which may be acounting processor.

In an alternative embodiment, the scale 110 and the imaging table 114are integrated into a single unit, such that there is no need for step214 to dispense the sample 140 from the scale 100 to the imaging table114.

In another alternative embodiment depicted in FIG. 10, one or moreseparate pipings 1002 of products 106 may be operated in parallel withpiping 104. Thus, multiple paths of products 106 may be simultaneouslyused and utilized, all relying on the data from the first path of piping104.

In operation, the processor 112 determines the number ofacceptably-sized products 106 on the imaging table 114 from an imagereceived from the camera 116, based on identification of the edges ofthe products 106 on the imaging table 114, which identify products 106within an acceptable size range. The acceptable range of sizes ofproducts 106 may be defined in the processor 112 based on the productbeing dispensed, or may be determined based on the size of imagedproducts, i.e., those within a range of sizes within a deviation,preferably those within one standard deviation of the mean size.

The identification of the size of the products 106 is accomplished, inpart, due to the construction of the imaging table 114. As depicted inFIG. 5, the imaging table 114 includes a surface 138, which is at leasttranslucent to light and which is illuminated from below. Thisillumination may be from any light source 504, but preferably one thatprovides a relatively consistent and sufficiently high level ofillumination. The light from light source 504 is preferably diffused atthe imaging surface 138 to provide consistent illumination. Thisdiffusion may be accomplished by a diffuser 506 integrated into thesurface 138 or below it. As a result, the diffused illumination at thesurface 138 of the imaging table 114, when covered with the products106, provides a dichromatic image wherein the products 106 appear blackagainst a white background. To reduce clumping or layering of theproducts 106 in the sample 140, the surface 138 of the imaging table 114may be associated with a vibrating device, such as eccentric motor, thuscausing the surface 138 of the imaging surface 138, and the products 106thereon, to vibrate and thus separate the products 106 from one anotherto avoid the products 106 clumping together or climbing atop oneanother. The imaging surface 138 of the imaging table 114 may include aninclined transparent lip or ridge 516 about the surface perimeter 514 ofthe imaging table 114, on which the products 106 cannot rest, to betterprovide an extensive translucent surface for the imaging surface 138 andavoid the potential for the edge of a product 106 to be adjacent anon-translucent surface such as the edge of the imaging table 114, whichwould create difficulty in identifying the edges of the products 106.Moreover, the inclined transparent lip or ridge 516 may be raisedsufficiently, or may have extended sides, to prevent the products 106from bouncing off the imaging table 114 when transferred from the scale110. Additionally, the imaging table 114 may include one or more airjets 518 aimed the imaging surface 138 at or near the corners of lip orridge 516 to better force products 106 away from the edges of imagingtable 114. The vibratory feeder 520 or other device may also be used toshift the products 106 about the imaging table 114 between images fromcamera 116, thus providing a different presentation of products 106 forsubsequent review.

Referring to FIG. 1, the acceptable-size of the products 106 used foridentification may be pre-programmed, or may be determined by theprocessor 112 as the mean size of the products 106 initially identifiedby the processor 112 upon review of data from camera 116.

Additionally or alternatively, the imaging surface 138 of the imagingtable 114 may be illuminated from above by a light 142 for assessment ofthe products 106 deposited on the imaging table 114. When used, the datafrom the camera 116 is assessed by processor 112 to identify those areasof the imaging table 114 which are covered by an object sufficientlydifferent in color, which may be bad products (such as rotted seed),rocks, or other contaminates. These objects can be subtracted oreliminated from the image by processor 112 before identification orassessment of the mean product size and/or the counting of products.

Returning to the product count, in determining the product count,clusters of products, which generate an image clearly beyond theaccepted distribution from the acceptable product size, are not counted.Similarly, broken products or other undesirable constituents, to theextent not already removed, will not be counted to the extent they arebelow the accepted distribution from the acceptable seed size. This isaccomplished by processing of the image by processor 112, which isadapted to identify each acceptable product 106 in the sample 140 withinthe acceptable product size range and to determine the number ofacceptable products 106.

Referring to FIGS. 1 and 6, once those products 106 fitting within theacceptable product size range are counted, step 604 of FIG. 6, processor112 filters the image, first removing the image of those products 106which were counted and those that fall below the acceptable productsize, step 606, i.e., subtracting those areas, and then using a knownmorphological technique, such a erosion, to reduce the size of theproducts 106 in the remaining product clusters in the image, step 608,until the image of the products 106 is sufficiently eroded for a furthercount, step 610. Processor 112 must therefore be adapted to perform amorphological erosion on the image of the products 106 outside theacceptable size range until at least some of the products 106 above theacceptable size range appear separated and to determine the number ofseparated eroded images of products 106. Clumps or collections ofproducts 106 are therefore reduced to individual product images. Theprocessor 112 then counts the identified products 106, step 612,repeating the process of erosion, step 608, assessment, step 610, andcounting products 106 on the image, step 612, on the image until allproducts 106 have been removed. Ideally no more than six repetitions areperformed on an image due to time constraints. Processor 112 may thencombine the number of acceptable products 106 within the sample 140within the acceptable size range and the number of separate productsidentified by the erosion to determine a sample count.

To reduce error, the process, steps 606-612, may be repeated on afurther copy of the image or multiple images recorded or photographstaken, potentially with different structuring elements to providepotentially differing product counts. A statistical point in thedistribution of the identified product count(s) may then be used, whichmay be the mean, a point below the mean, thus providing a higherapproximate product count, or a point above the mean, thus providing alower product count.

Where the morphological operation used is erosion, pixels are removed onobject boundaries. As is known, the number of pixels added or removedfrom the objects in an image depends on the size and shape of thestructuring element used to process the image. For most products acircular matrix is sufficient; however in some instances a perpendicularintersection of two lines is better. The latter, for example, is helpfulin erosion of an image of corn kernels, largely due to the variation inkernel size and irregular geometry. In action, the processor 112assesses each pixel or grid section in the image based on thesurrounding pixels. The grid size applied by the processor is defined bythe user and is typically a grid created by two perpendicular axes. Asdepicted in FIG. 7, because of the contact between the various products106, and therefore the edges touching and forming one continuos object,on the imaging surface 138, processor 112 may initially determine onlytwo products are present. As depicted in FIG. 7, when processor 112assesses cell 742 based on a circular matrix, it considers whether allcells 731, 732, 733, 741, 743, 751, 752 and 753 contain data, part of aproduct 106, a binary “1”. As cell 741 does not contain data but ratheris empty, the value of cell 742 is determined to be set to zero uponcompletion of the assessment; i.e., all data removed, of the entireimage, thus eroding the edge of product 106 associated with cell 742 inthe revised image. The processor 112 then continues across the image tothe next cell, 743, and assesses the cell based on the original image.The processor 112 then assesses the eroded image to determine the numberof products 106 present, which have been reduced in size and, hopefully,separated from the former clusters by erosion of the associated edges ofthe products 106 in the cluster. The result is identification of theproducts present, such as on FIG. 8, which after erosion through one ormore iterations, separates the products 106 to identify the actual countof ten (10) products 106. For those clusters not separated by the firsterosion, further erosions may be performed on the image(s) until allclusters of products have been reduced to individual product images. Thespeed and accuracy of this erosion can be adjusted based on theresolution of the camera 116 used and the size and configuration of thematrix used for erosion.

Referring to FIG. 5, imaging table 114 is preferably rotatably mountedto permit the products 106 associated with the sampling volume 108imaging table 114 to be dispensed to a sample output piping 118, withwhich imaging table 114 is in communication, after processor 112determines the count of products 106 of sampling volume 108, step 220 ofFIG. 2. Imaging table 114 may be hingely mounted on pivots 508 connectedto a support frame 522 and maintained in position by a piston 510attached to the imaging table 114 and the support frame 522 or may berotatably mounted and rotated about an axis. In a further alternative, abrush 512 or plow may be associated with imaging table 114 to push theproducts 106 off the imaging table 114 for delivery to the sample outputpiping 118 or to ensure all products 106 are removed from the imagingtable 114. In each instance, the imaging table 114 is preferably emptiedin response to a signal from the processor 112, but may be constructedto empty after a uniform time period.

Referring to FIG. 1, after products 106 of sampling volume 108 areremoved from the imaging table 114 and communicated to sample outputpiping 118, which may return the products 106 to the bin or piping 104.

Returning to FIGS. 1, 2, and 3, once a count of products 106 in theweight of sample 140 is known, the product density value of the products106 associated with a zone, such as zone 122 is established by dividingthe sample count, step 220 of FIG. 2, by the sample weight, step 212 ofFIG. 2, which is accomplished at step 222 of FIG. 2. Density may bedetermined in a processor 112, which may be a density processor adaptedto determine the product density value of a zone of preferable smallfungible products within an acceptable size range by dividing the samplecount by the sample weight value. Beneficially, as the time forobtaining the sample weight, step 212 of FIG. 2 and the sample count,step 220 of FIG. 2 can be quite short, the product density value may beobtained rapidly, such as nearly instantaneously, which may also bereferred to as obtaining the product density value in real time, or innear real-time. As a result, the product density value of a zone 122 inbin 104 may be determined in less than a minute, and preferably thevalue of product densities of three nearby zones 122 may be obtainedwithin a minute. Desirably, the time frame should be less than fiveseconds. Most particularly, the product density value of a zone 122 in aflow of products 106 is ideally determined and output to a product flowcontroller 144 controlling a flow control device, such as thebagger/scale 120 or a gate, before the zone 122 reaches the flow controldevice, thus providing the product density value in real time. Whenneeded, a desired minimum weight associated with the desired quantitymay be obtained by dividing the desired quantity by the product densityvalue, step 224 of FIG. 2. In those instances when an automated baggeris associated with and directly connected to the invention, which is notrequired, when the products 106 of the zone 122 associated with thesampling volume 108 reach the bagger/scale 120, the processor 112, whichmay be a bag-weight processor, activates the bagger/scale 120 andreceives a signal from bagger/scale 120 associated with the weightreading output from the bin or piping 104, step 226 of FIG. 2. Theprocessor 112, as a bag-weight processor, is adapted to determine thedesired weight associated with a desired quantity of product by dividingsaid desired quantity by said product density value. When the weightreading output from the bagger/scale 120 to the processor 112 reachesthe weight associated with the desired product count, bagger/scale 120ceases to feed product 106 to the bag 124, step 228 of FIG. 2. Thus, thebagger/scale 120 is adapted to transmit the actual bag weight to theprocessor 112, which is adapted to compare the actual bag weight to saiddesired weight. The processor 112 is further adapted to terminateoperation of the bagger/scale 120 when the actual bag weight isequivalent to the desired weight.

A larger product plant-based system may alternatively receive theproduct density value data and via a product flow controller 144 controlthe bagger/scale 120. Thus the density calculation may be accessed by aplant information system or an automated packaging system. Similarly,the desired weight may be displayed on a display associated with amanual bagger, permitting the operator to feed the correct weight ofproduct into the bag. Further, the data associated with a zone 122, andtherefore with a product from a particular supplier may be retained in aproduct plant-based system for historical purposes or quality control,such as average size, quality of product, or percentage of contaminants.Thus, the imaged information may be stored for future analysis, auditsupport, and process improvement activities in a storage component, suchas computer-readable media, such as hard drives, diskettes, and flashmemory. With such data, the plant operator can better select suppliersand ensure higher quality product and lower contamination, which slowsprocessing and increases cost.

As can be appreciated, this weight and imaging process permits theproduct density value to be determined several times per minute,resulting in data in real-time or near real-time, i.e., at approximatelythe same time the product 106 passes through the system withoutsubstantial delay, thus permitting the operation of any equipment on theproduct flow line, such as a bagger/scale 120, to be operated at thetime the zone 122 associated with the sample 140 reaches the equipment,thus avoiding or addressing potential variations of product densityvalue in various zones 122 in bin or piping 104.

The terms and expressions which have been employed in the foregoingspecification are used therein as terms of description and not oflimitation, and there is no intention, in the use of such terms andexpressions, of excluding equivalents of the features shown anddescribed or portions thereof.

1. A system for determining in near real-time the product density valueof a zone of preferable small fungible products within an acceptablesize range in a flow of products and for outputting said product densityvalue to a product flow controller before said zone reaches a flowcontrol device, comprising: a sampling container, said samplingcontainer having an internal volume, said internal volume of saidsampling container defining a sample when filled with products; a weightscale, said weight scale positioned below said sampling container andpositioned to receive said sample from said sampling container; saidweight scale adapted to transmit a sample weight value to weightprocessor, said sample weight value indicative of the weight of saidsample; an imaging table, said imaging table below said weight scale andpositioned to receive said sample from said weight scale; a camera, saidcamera adapted to transmit at least one image of said imaging table to acounting processor; said counting processor adapted to identify eachacceptable product in said sample within said acceptable size range anddetermining the number of said acceptable products, said countingprocessor adapted to perform a morphological erosion on said at leastone image of said products above said acceptable size range until atleast some of said products above said acceptable size range appearseparated and of determining the number of said separated products, andadapted to combine the number of said acceptable products of said samplewithin said acceptable size range and said number of said separatedproducts to determine a sample count; and a density processor adapted todetermine said product density value by dividing said sample count bysaid sample weight value.
 2. The system of claim 1, further comprising alight illuminating said imaging table surface from above and whereinsaid counting processor is adapted to distinguish the products of saidsample within a desired color range and adapted to eliminate fromidentification those products outside the desired color range.
 3. Thesystem of claim 1, further comprising a support frame, said imagingtable hingedly affixed to said support frame, and a piston, said pistonaffixed to said weight scale and said support frame.
 4. The system ofclaim 1 further comprising storage of said product density value foraccess by a plant information system or an automated packaging system.5. The system of claim 1 further comprising storage of said at least oneimage of each of said sample.
 6. The system of claim 1, wherein saidsampling container further comprises a top gate and bottom gate.
 7. Thesystem of claim 6, further comprising a sample input piping, said sampleinput piping having a first end and a second end, said sample inputpiping adapted for communication with said sampling container at saidsample input piping second end, said sample input piping adapted forcommunication with a bin of products, said products in one or more ofsaid zones in said bin, said products in each of said one or more ofsaid zones having nearly equivalent characteristics of size, weight andpercentage of desired products.
 8. The system of claim 7, furthercomprising a vibratory feeder, said vibratory feeder connected to saidsample input piping.
 9. The system of claim 1, wherein said weight scaleis a dump scale.
 10. The system of claim 1, wherein said imaging tableincludes an imaging table surface, said imaging table surface at leasttranslucent to light, said imaging table surface illuminated from belowsaid imaging table surface.
 11. The system of claim 10 wherein saidimaging table includes an inclined translucent lip about said imagingtable surface.
 12. The system of claim 11, further comprising avibratory motor, said vibratory motor connected to said imaging table.13. The system of claim 12, wherein said imaging table further includesat least one air jet aimed at said imaging table surface.
 14. The systemof claim 12, further comprising a damping device to slow said product,said damping device positioned between said weight scale and saidimaging table.
 15. The system of claim 14, wherein said damping devicecomprises a plurality of spaced-apart pegs.
 16. The system of claim 13,further comprising a bag-weight processor adapted to determine thedesired weight associated with a desired quantity of product by dividingsaid desired quantity by said product density value; a bagger, saidbagger adapted to transmit the actual bag weight to said bag-weightprocessor, said bag-weight processor comparing said actual bag weight tosaid desired weight; and said bag-weight processor adapted to terminateoperation of said bagger when said actual bag weight is equivalent tosaid desired weight.
 17. A method for determining in near real-time theproduct density value of a zone of preferable small fungible productswithin an acceptable size range in a flow of products and for outputtingsaid product density value to a product flow controller before said zonereaches a flow control device, comprising: obtaining a sample from aflow of mixed products; determining a sample weight of said sample;imaging said sample to produce at least one image; processing said atleast one image to identify and count the individual preferred smallfungible products within said acceptable size range, to identify areasof said image containing objects larger than the small preferred smallfungible products within said acceptable size range, and to retain onlysaid areas of the at least one image containing objects larger than thepreferred small fungible products within said acceptable size range;repeatedly processing said at least one image to morphologically erodesaid objects larger than the preferred small fungible products withinsaid acceptable size range, to identify the mean size of the erodedobjects, determining an acceptable eroded object size about said meansize, processing said at least one image to identify and count theeroded objects within said acceptable size, and to retain only saidareas of the at least one image containing eroded objects larger thansaid acceptable size, until no eroded objects remain; combining saidcount of the number of said individual preferred small fungible productsand said count of the number of eroded objects within said acceptablesize to produce a sample count; determining said product density valueby dividing said sample count by said sample weight value; andoutputting said determination of product density value to a product flowcontroller and the plant information system.
 18. The method of claim 17,wherein repeatedly processing said at least one image to morphologicallyerode said objects larger than the preferred small fungible productscomprises: applying a grid to said at least one image to create aplurality of cells; selecting a grid cell from said grid; selecting amatrix of grid cells surrounding said grid cell; assessing whether saidcells in said matrix of cells all contain data; selecting another gridcell from said grid; selecting a another matrix of grid cellssurrounding said another grid cell; assessing whether said cells in saidanother matrix of cells all contain data; deleting any data from saidgrid cell if said cells in said matrix do not all contain data; anddeleting any data from said another grid cell if said cells in saidanother matrix do not all contain data.
 19. The method of claim 17further comprising storing said product density value for access by aplant information system or an automated packaging system.
 20. Themethod of claim 17 further comprising storing said least one image ofeach of said sample.
 21. A method for obtaining a desired quantity ofpreferred small fungible products from a flow of mixed products,comprising: obtaining a sample from a flow of mixed products;determining a sample weight of said sample; imaging said sample toproduce at least one image; processing said at least one image toidentify and count the individual preferred small fungible productswithin an acceptable size range, to identify areas of said imagecontaining objects larger than the small preferred small fungibleproducts within said acceptable size range, and to retain only saidareas of the at least one image containing objects larger than thepreferred small fungible products within said acceptable size range;repeatedly processing said at least one image to morphologically erodesaid objects larger than the preferred small fungible products withinsaid acceptable size range, to identify the mean size of the erodedobjects, determining an acceptable eroded object size about said meansize, processing said at least one image to identify and count theeroded objects within said acceptable size, and to retain only saidareas of the at least one image containing eroded objects larger thansaid acceptable size, until no eroded objects remain; combining saidcount of the number of said individual preferred small fungible productsand said count of the number of eroded objects within said acceptablesize to produce a sample count; determining said product density valueby dividing said sample count by said sample weight value; determiningthe desired weight associated with the desired quantity by dividing saiddesired quantity by said product density value; activating a baggerassociated with said flow of mixed products, said bagger transmitting anactual bag weight to said final processor, said final processorcomparing said actual bag weight to said desired weight; and terminatingoperation of said bagger when said actual bag weight is equivalent tosaid desired weight.
 22. The method of claim 21 further comprisingstoring said product density value for access by a plant informationsystem or an automated packaging system.
 23. The method of claim 21further comprising storing said at least one image of each of saidsample.